PL210165B1 - Embossed decorative boards - Google Patents

Abstract

Embossed decorative boards having first and second opposite edges with a third and a fourth adjacent edge. The board includes an upper side decorative surface an upper side embossing and a base layer. The embossing is comprised by surface structure areas of which at least four are first and second outermost surface structure areas. The first outermost surface structure area has each one end edge coinciding with the first edge of the board while the second outermost surface structure area has each one end edge coinciding with the second edge. At least two surface structures having different visual characteristics are used, wherein two adjacent outermost surface structure areas within the same board have different surface structures. The end edge of the outermost surface structure areas with the same ordinal number of the first edge and the second edge has mainly the same length while the surface structure is similar.

Description

The invention relates to an embossed decorative plate, in particular decorative plates provided with a surface structure on the upper surface.

There are currently known products coated with thermosetting laminates, which are most often used where there are requirements for high abrasion resistance, and also where resistance to various chemicals and moisture is required. Examples of such products are flooring, decorative floor rollers, table tops and wall panels.

A thermosetting laminate consists of a series of base sheets with the decorative sheet placed closest to the surface. The decor sheet may be provided with a desired ornament or pattern. The most common patterns are usually images of different types of wood or minerals such as marble or granite. The surface of the laminate may be provided with a structure during the lamination process which makes the pattern more realistic. In the production of such a laminate, structured press plates or structured films are often used. The negative reproduction of the structure in the press plate or film is then impressed into the laminate by a lamination process.

The structure corresponds to the characteristics of the pattern represented in the laminate. The structure can be made as a coarse structure to simulate, for example, rough ground stone, or as a smooth structure with randomly distributed indentations and micro-cracks to simulate polished marble. For example, a wood surface can be imitated by providing the surface with randomly spaced thin longitudinal indentations which imitate pores. In order to obtain a realistic effect, these indentations must be oriented in the direction of growth of the imitated wood, which is indicated by the grain patterns.

US Patent No. 5,744,220 discloses a thermosetting decorative laminate that can be used as a floor laminate. The laminate comprises two or more layers, at least one of these layers is a decorative layer comprising decorative paper provided with a strip pattern comprising a plurality of parallel rows of strips, the strips in adjacent rows being spaced apart in the length direction. The disclosed stripe pattern allows the laminate to be divided into a plurality of elongated units or panels each comprising several rows of strips. The pattern of each stripe at the left end matches the pattern of the corresponding right end stripe in each unit or panel, and the patterns of the strips match the corresponding end strips in the corresponding rows of all units or panels. The above-described laminate can be made into floorboards, however, the disclosed laminate does not have the different visual characteristics of the decorative layer used, due to the reflective properties of its decorative structure.

There has long been a great need to be able to produce a decorative patterned thermosetting laminate with a surface structure as similar to "living, ie natural" as the reproduced decorative structure.

A embossed decorative panel having a first edge and an opposite second edge with adjacent third and fourth edges, the panel having a decorative surface on the upper side, embossing on the upper side and a base layer, which embossments are formed by surface structure areas at least two of which are the first outermost surface structure regions, and at least two are the second outermost surface structure regions, each of the first outermost surface structure regions having an end edge coinciding with the first plate edge, and the second outermost surface structure regions each having an end edge. coinciding with the second edge which is opposed to the first edge, furthermore the surface structure regions have at least two surface structures which have different visual features, two adjacent outermost The surface structure areas, respectively, in the same plate have different surface structures, the different surface structures preferably being arranged in groups of surface structures according to their visual characteristics, the first extreme areas of the surface structure of the first edge being given the order number I, II, III ... and the subsequent next, starting from the third edge, and the second outermost areas of the surface structure of the second edge have the ordinal numbering I, II, III ... and a further subsequent one, starting from the third edge, the ending edge of the first and the other extreme

The outermost surface structure regions of the same ordinal numbering I, II, III ... of the first end edge and the second end edge, respectively, preferably have the same length, while the outermost surface structure region having the same numbering. the ordinal I, II, III ... of the first edge and the second edge have a similar surface structure, according to the invention, it is characterized in that similar surface structures have the same visual characteristics, the different visual characteristics being formed by the micro-structures used to obtain the matte or a semi-gloss surface, and the embossing is formed by a flat surface with recesses.

Preferably, the decorative surface comprises a plurality of conventional dry base layer paper webs or base layer paper sheets which are impregnated with a thermosetting resin, the resin in the extreme web or sheet preferably being melamine-formaldehyde resin, while the remaining webs or sheets preferably contain melamine resin. -formaldehyde or phenol-formaldehyde resin, a decor paper web or a decorative paper sheet, respectively, is placed on top of the conventional base layer webs or sheets of the base layer, and the different paper webs or sheet stack, respectively, are continuously or discontinuously laminated to each other under conditions. increased pressure and at elevated temperature.

Preferably, the base layer comprises a fibreboard or a particle board.

Preferably, the decorative pattern consists of a number of sections of parallel rows of slats, the slats in adjacent rows being offset in the longitudinal direction from one another.

Preferably, a demarcation is provided between adjacent areas of the structure consisting of a field 1-20 mm wide, in particular 3-10 mm wide, free of any surface structure.

Preferably, the demarcation consisting of a field 1-20 mm wide, in particular 3-10 mm wide, is a surface structure which gradually transforms into another surface structure.

Preferably, the surface layer of the laminate comprises a so-called overlay paper placed on top of the decor paper.

Preferably, the overlay paper is impregnated with a melamine-formaldehyde resin.

Preferably, at least one of the sheets impregnated with a thermosetting resin, preferably an end sheet, is coated with hard particles, for example silica, alumina and optionally silicon carbide, with an average size of from 1 to 100 µm, preferably from about 6 to 60 µm.

Preferably, the decorative surface of the upper side is formed of a decorative layer and an ionomeric polymer.

Preferably, the decorative surface of the upper side is formed of a decorative layer, an ionomeric polymer and hard particles.

Preferably, the decorative surface of the upper side consists of a decorative layer, an ionomeric polymer, an overlay paper impregnated with melamine-formaldehyde resin and hard particles.

Preferably, the decorative layer is made of paper.

A preferred effect of the invention is to provide a decorative surface with a decorative surface with a matching surface structure overlapping adjacent boards. The embossed decorative boards according to the invention have opposing first and second edges, with adjacent third and fourth edges. The boards have a decorative surface on the upper side, embossments on the upper side and a base layer, an advantage of the invention that the embossments consist of surface structure regions, at least four of which are the first and second extreme surface structure regions. Each first extreme area of the surface structure has an end edge coinciding with a first edge of the plate, and each second extreme area of the surface structure has an end edge coinciding with a second edge of the plate. The second edge is opposite the first edge. At least two surface structures are used which have different visual characteristics, two adjacent extreme areas of the surface structure inside the same panel having different surface structures. The different surface structures can be arranged in groups of surface structures according to their visual characteristics, whereby the first outermost regions of the surface structures of the first edge are subsequently numbered U, U, L ¹¹¹ , etc. starting from the third edge. The second extreme areas of the structure

The surface second edges are subsequently numbered R, R ¹¹ , R ¹¹¹ , etc. starting from the third edge. The end edge of the outermost areas of the surface structure with the same ordinal number of the first edge and the second edge here has substantially the same length. The outermost area of the surface structure with the same ordinal number of the first edge and the second edge has a similar surface structure.

According to one embodiment of the invention the base layer may consist of a number of conventional dry base layer paper webs or base layer paper sheets which are impregnated with a thermosetting resin. The resin is preferably located in the uppermost one, while the rest of the webs or sheets may, for example, contain a melamine-formaldehyde resin or a phenol-formaldehyde resin. Suitably, the decorative paper web or decorative paper sheet is placed on top of conventional base layer webs or base layer sheets, and the various paper webs or a stack of sheets, respectively, are continuously or discontinuously (intermittently) laminated to each other under increased pressure and elevated temperature.

The surface layer may suitably comprise a so-called overlay paper placed on top of the decor paper. The overlay paper is suitably impregnated with melamine-formaldehyde resin. At least one of the sheets impregnated with a thermosetting resin, preferably an end sheet, is preferably coated with hard particles, for example silica, alumina and optionally silicon carbide, with an average size of from 1 to 100 µm, preferably from about 5 to 60 µm.

The overlay may alternatively be replaced or used together with an ionomeric polymer layer in which the polymer is formed from, for example, ethylene-methacrylic acid copolymer and the ions are derived from, for example, sodium, zinc or lithium, although other ionomeric polymers may also be used. As described above, it is preferred to use hard particles in the present embodiment.

According to one embodiment of the invention, the base layer consists of a fibreboard or particle board, and the base layer may have a thickness of 5 to 20 mm.

According to an embodiment of the invention, the decorative pattern consists of a series of sections, parallel rows of stripes or bars, the stripes in adjacent rows being offset from each other in the longitudinal direction. The most popular decoration used on floor slabs is various types of wood and minerals. The surface structures have narrow surface indentations 0.1-10 mm wide that mimic pores, cracks, rings, knots and knots. It is also possible to use microstructures giving matt or semi-gloss surfaces. The latter can be used in conjunction with the above structures.

According to a further embodiment of the invention, a demarcation is provided between adjacent areas of the structure consisting of a field 1-20 mm wide, preferably 3-10 mm wide, without any surface structure.

According to an alternative embodiment of the invention, a demarcation consisting of a field 1-20 mm wide, in particular 3-10 mm wide, is one surface structure gradually merging into another surface structure.

The subject of the invention in the exemplary embodiments is shown in the drawing, in which Fig. 1 shows a pressed decorative panel in the form of a floor panel in an embodiment of the invention, Fig. 2 - end parts of two embossed decorative panels according to the invention, schematically, Fig. 3, a rectangular embossed decorative panel according to the invention. of a second embodiment of the invention, diagrammatically, Fig. 4 - a square embossed decorative panel according to a third embodiment of the invention, diagrammatically, Fig. 5 - a rectangular embossed decorative panel according to a fourth embodiment of the invention, diagrammatically, Fig. of the invention, schematically, fig. 7 - a rectangular embossed decorative panel according to a sixth embodiment of the invention, schematically, fig. 8 - parts of the embossed decorative panel corresponding mainly to the embodiment shown in fig. 1, schematically, and fig. according to v of the invention, schematically.

The embossed decorative board 1 in the first embodiment, shown in FIGS. 1 and 8 schematically as a floor plate which has a first edge 1 and a second opposite edge 1 with the third and a fourth adjacent edge respectively Y 1 ^V decorative board 1 has a decorative surface 2 upper sides, embossing on the upper side and a base layer. The embossing consists of a flat surface with recesses, which are marked in black in the drawing

PL 210 165 B1 by lines. The embossments are formed by areas of the surface structure 10 of which at least four are the first and second extreme areas of the surface structure, denoted respectively ^10L and ^10R . For the sake of simplification, only the extreme areas 10 ^L and 10 ^{R of} the surface structure, respectively, are provided with the structure shown in the drawing. Each first extreme region 10 ^{L of} the surface structure has an end edge coinciding with the first edge 1 of the decorative panel 1, and each second extreme region 10 ^{R of} the surface structure has an end edge coinciding with the second edge 1 '. The second edge 1 is opposed to the first edge F. At least two surface structures are used which have different visual characteristics, the two adjacent respectively edge regions 10 ^L and 10 ^{R of} the surface structure in the same decorative panel 1 having different surface structures. The different surface structures are arranged in the surface structure groups according to their visual characteristics, whereby the first edge areas 10 ^{L of} the surface structure of the first edge 1 are subsequently numbered U, L and L ¹¹ 'starting from the third edge Γ. The second extreme areas 10 ^{R of} the surface structure of the second edge 1 are subsequently numbered R, R, R "" starting from the third edge 1]. The end edge of the end areas 10 ^L and 10 ^{R of} the surface structure with the same ordinal number of the first edge 1 and the second edge 1 ^, respectively, has substantially the same length Δ (see Fig. 8), while the end area 10 ^L and 10 ^{R of the} structure are with the same ordinal number of the first edge 1 and the second edge 1 have a similar surface structure. As shown in Figure 8, the length of AL ¹ is substantially the same as the length of AR ', the length of AL "is substantially the same as the length of AR", and the length of AL ¹¹¹ is substantially the same as the length of AR ". '.

Fig. 2 shows the end portions of two embossed decorative panels 1 in the form of floor panels before joining. The decorative plates 1 have a first edge 1 and a second opposite edge 1 with third and fourth adjacent edges 1 "" and 1 ^{V, respectively} . The decorative plates 1 have a decorative surface 2 on the upper side, an embossing on the upper side and a base layer. The embossing is formed by a flat surface with indentations which are represented in the figure by black lines. The embossments are formed of surface structure areas 10 of which at least four are the first and second extreme areas 10 ^L and 10 ^{R of} the surface structure, respectively. Each first end region 10 ^{L of} the surface structure has an end edge coinciding with the first edge 1 of the decorative panel 1, and each second end region 10 ^{R of} the surface structure has an end edge coinciding with the second edge 111. The second edge 1 is situated opposite the first edge F At least two surface structures are used which have different visual characteristics, two adjacent edge areas 10 ^L and 10 ^{R of} the surface structure, respectively, in the same plate 1 having different surface structures. The various surface structures are arranged in groups of surface structures according to their visual characteristics, the first edge areas 10 ^{L of} the surface structure of the first edge 1 are subsequently numbered U, R and L "" starting from the third edge 1 "". The second extreme areas 10 ^{R of} the surface structure of the second edge 1 are subsequently numbered RR, R "" starting from the third edge 1]. The end edge of the end areas 10 ^L and 10 ^{R of} the surface structure, respectively, with the same ordinal number of the first edge 1 and the second edge 1 are substantially the same length, and the end areas 10 ^L and 10 ^{R of} the surface structure, respectively, of the same ordinal number the first edge 1 and the second edge 1 have a similar surface structure.

Figure 3 shows schematically a rectangular embossed decorative panel 1 with a short edge to long edge ratio of one to six (1: 6). The embossing consists of a flat surface with indentations, which are shown in black lines in the drawing. The embossments are three longitudinal rows of surface structure areas 10, with three different types being used. Surface structures. The plate 1 shown in FIG. 3 largely corresponds essentially to that shown in FIGS. 1 and 2 above.

Fig. 4 shows schematically a square embossed decorative panel 1. The embossings consist of a flat surface with indentations, which are represented in the drawing by black lines. The embossings are three longitudinal rows of surface structure areas 10, punctuated by a narrow diagonal stripe or line, and four different types of surface structures are used. The decorative plate 1 shown in Fig. 3 corresponds essentially to the embodiment shown in Figs. 1, 2 and 3 above.

PL 210 165 B1

Figure 5 shows schematically a rectangular embossed decorative panel 1 with a short edge to long edge ratio of one to six (1: 6). The embossing is a flat surface with indentations, which are represented by black lines in the figure. The embossments are two longitudinal rows of surface structure areas 10, and three different types of surface structures are used. The various surface structures are arranged in groups of the surface structures according to their grain direction, the first edge regions 10 ^{L of} the surface structures of the first edge 1 are subsequently numbered L and L 'starting from the third edge 1 ^HI . Second end areas 10 of the surface structure of the ^R edge 1 of the second are subsequently numbered R ^I and R starting from the third edge 1 ^IH. The end edge of the edge zones 10 ^L and 10 ^R of the surface structure, respectively with the same ordinal number of the first edge 1 and the second edge 1 has substantially the same length while the surface structure of the periphery of the 10 ^L and 10 ^R of the surface structure, respectively, of the the same ordinal number of the first edge 1 and the second edge 1 have a similar surface structure.

Fig. 6 shows schematically a rectangular embossed decorative panel 1 with a short edge to long edge ratio of one to six (1: 6). The embossing is a flat surface with indentations, which are represented by black lines in the figure. The embossing shows three longitudinal rows of surface structure areas 10, and three different types of surface structures are used. The decorative plate 1 shown in Fig. 6 corresponds essentially to the above-mentioned Figs. 1, 2 and 3. The middle row is however narrower, while the first and third rows are wider.

Fig. 7 shows schematically a rectangular embossed decorative panel 1 with a short edge to long edge ratio of one to six (1: 6). The embossing is a flat surface with indentations, which are represented by black lines in the figure. The embossing shows rhomboidal surface structure regions 10 in which three different types of surface structures are used.

Fig. 8 is described together with Fig. 1 above.

Fig. 9 shows schematically the embossing of an installed floor covering consisting of rectangular decorative panels 1 according to the invention. The decorative plates 1 used mainly correspond to the solution shown in Fig. 3. The joints between the decorative plates 1 are shown in the drawing with thicker lines. The decorative panels 1 have three longitudinal rows of surface structure areas 10, of which the outermost areas 10 ^L and 10 ^R are respectively arranged such that the first row B ^{I of} each decorative panel 1 ends with a type I surface structure on both short lateral sides. end, while the second and third row, respectively, B ¹¹ and B ¹¹¹ ends with surface structure type II, respectively, and III. The intermediate surface structure regions 10 are arranged in a random order, as long as two adjacent surface structure regions 10 of the same row do not have the same type of surface structure.

The invention is not limited to the above embodiments which can be varied in various ways within the framework of the invention.

Claims (13)

1.A embossed decorative panel having a first edge and an opposite second edge with adjacent third and fourth edges, the panel having a decorative surface on the upper side, embossing on the upper side and a base layer, the embossments being formed by surface structure regions of which at least two are the first outermost surface structure regions, and at least two are the second outermost surface structure regions, each of the first outermost surface structure regions having an end edge coinciding with the first plate edge and each of the second outermost surface structure regions having an end edge coinciding with the second edge which is opposed to the first edge, furthermore the surface structure regions have at least two surface structures which have different visual features, two adjacent outer outermost extremities that the surface structure regions, respectively, in the same plate have different surface structures, which different surface structures are preferably arranged in groups of surface structures according to their visual characteristics, with The first outermost areas of the surface structure of the first edge are given the order numbering I, II, III ... and a further subsequent one, starting from the third edge, and the second outermost areas of the surface structure of the second edge are given the order numbering I, II, III. ... and a further further, starting from the third edge, the end edge of the first and second outermost surface structure regions respectively with the same ordinal numbering I, II, III ... of the first end edge and the second end edge preferably has , the same length, while the outermost area of the surface structure with the same ordinal number I, II, III ... of the first edge and the second edge has a similar surface structure, characterized in that similar surface structures have the same visual characteristics, but the different visual features are formed by the microstructures used to obtain a matt or semi-gloss surface surface, and the embossments are formed by a flat surface with recesses. 2. The plate according to claim The method of claim 1, characterized in that the decorative surface (2) comprises a plurality of conventional dry base layer paper webs or base layer paper sheets which are impregnated with a thermosetting resin, the end web or sheet resin preferably being a melamine-formaldehyde resin and the other webs or the sheets preferably contain melamine formaldehyde resin or phenol formaldehyde resin, and a decor paper web or a decorative paper sheet, respectively, is placed on top of the conventional base layer webs or sheets of the base layer, and the different paper webs or sheet stack, respectively, are laminated to each other. continuously or discontinuously under elevated pressure and temperature conditions. 3. The plate according to claim The method of claim 1, characterized in that the base layer comprises a fibreboard or a particle board. 4. The board according to p. 6. The decorative pattern according to claim 1, characterized in that the decorative pattern consists of a plurality of sections of parallel rows of slats, the slats in adjacent rows being offset from each other in the longitudinal direction. 5. The board according to p. 3. A line according to claim 1, characterized in that between adjacent areas (10, 10 ^LI , 10 ^UI , 10 ^LIH , W ^R , 101 10 ^Rm ) of the structure there is a demarcation consisting of a field 1-20 mm wide, in particular 3-10 mm wide. mm, free of any surface structure. 6. The board according to p. 5. The demarcation according to claim 5, characterized in that the demarcation consisting of a field 1-20 mm wide, in particular 3-10 mm wide, is a surface structure which gradually transforms into another surface structure. 7. The board according to p. 3. The surface of the laminate according to any of the preceding claims, characterized in that the surface layer of the laminate comprises so-called overlay paper placed on top of the decorative paper. 8. The board according to p. The overlay paper according to claim 7, wherein the overlay paper is impregnated with melamine-formaldehyde resin. 9. The board according to p. 7. The method of claim 7, characterized in that at least one of the sheets impregnated with a thermosetting resin, preferably an edge sheet, is coated with hard particles, for example silica, alumina and optionally silicon carbide, with an average size of from 1 to 100 μm, preferably from about 6 to 60 lim. 10. The board according to claim The device of claim 1, characterized in that the decorative surface (2) of the upper side is formed of a decorative layer and an ionomeric polymer. 11. The board according to p. 3. The apparatus of claim 1, characterized in that the decorative surface (2) of the upper side is formed of a decorative layer, an ionomeric polymer and hard particles. 12. The board according to p. The device of claim 1, characterized in that the decorative surface (2) of the upper side is formed of a decorative layer, an ionomeric polymer, an overlay paper impregnated with melamine-formaldehyde resin and hard particles. 13. The board according to p. 9, 10, 11 or 12, characterized in that the decorative layer is made of paper.